Sole Structure with Integrated Cleat Member and Methods of Making

ABSTRACT

A sole structure with an integrated cleat member includes a plate member with a protruding portion that forms a first portion of the cleat member. A second portion of the cleat member is attached to the first portion and may be made of a less rigid material than the first portion. A supporting structure can be disposed inside the protruding portion. A method of forming the sole structure can include reshaping a portion of a plate member to form a protruding portion, molding a cleat tip portion onto the protruding portion and molding a supporting structure into a concave inner portion of the protruding portion.

BACKGROUND

The embodiments relate generally to a sole structure with an integratedcleat member and methods of making the sole structure with theintegrated cleat member.

Articles of footwear having an outsole with cleats have previously beenproposed. In many cases, the outsole and cleat portions are frequentlysubjected to intense forces and stresses caused by repeated impact withthe ground. In some cases, cleats penetrate the ground surface exposingthe cleats and outsole to even more stress.

SUMMARY

In one aspect, a method of making a sole structure includes reshaping aportion of a plate member to form a protruding portion for a cleatmember, where the protruding portion has a convex outer portion and aconcave inner portion. The method also includes forming a hole in theprotruding portion, where the hole provides fluid communication betweenthe outer portion and the inner portion. The method also includesmolding a cleat tip portion onto the outer portion and molding asupporting structure within the inner portion. The cleat tip portion isconnected to the supporting structure through the hole.

In another aspect, a method of making a sole structure includesreshaping a portion of a plate member to form a protruding portion for acleat member, where the protruding portion has a convex outer portionand a concave inner portion. The method also includes filling the innerportion with a molding material to form a supporting structure. Theplate member is substantially more rigid than the supporting structure.

In another aspect, a sole structure includes a plate member made of afirst material, where the plate member has an upper surface and a lowersurface. The sole structure also includes a cleat member, where thecleat member further includes: a first portion that is integrally formedwith the plate member and includes a concave inner portion on the uppersurface of the plate member and a convex outer portion on the lowersurface of the plate member; a second portion attached to the firstportion, where the second portion is made of a second material; and asupport structure filling at least a portion of the concave innerportion, where the support structure is made of a third material. Thefirst material is substantially more rigid than the second material andthe first material is substantially more rigid than the third material.

Other systems, methods, features, and advantages of the currentembodiments will be, or will become, apparent to one of ordinary skillin the art upon examination of the following figures and detaileddescription. It is intended that all such additional systems, methods,features and advantages be included within this description and thissummary, be within the scope of the current embodiments, and beprotected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is an isometric view of a lower surface of an embodiment of asole member;

FIG. 2 is a top isometric view of an embodiment of a sole member;

FIG. 3 is a schematic view of an embodiment of a shaping assembly forforming protruding portions on a plate member;

FIG. 4 is a cross sectional view of an embodiment of a shaping assemblywith a plate member inserted between a top molding plate and a bottommolding plate;

FIG. 5 is a top down isometric view of an embodiment of a plate memberwith a plurality of protruding portions;

FIG. 6 is an isometric view of a lower surface of an embodiment of aplate member with a plurality of protruding portions;

FIG. 7 is a schematic view of an embodiment of holes being formed in aplurality of protruding portions on a plate member;

FIG. 8 is a schematic view of an embodiment of a molding assembly for aplate member;

FIG. 9 is a cross sectional view of an embodiment of a portion of aplate member disposed between a top molding plate and a bottom moldingplate;

FIG. 10 is a cross sectional view of an embodiment of a portion of aplate member disposed between a top molding plate and a bottom moldingplate with molding material filled in between the top molding plate andthe bottom molding plate;

FIG. 11 is an isometric view of an alternative embodiment of a solestructure including filling material;

FIG. 12 is a cross sectional view of an embodiment of a process ofmolding material onto a protruding portion without holes; and

FIG. 13 is an isometric view of an embodiment of a sole structure.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose a solestructure for an article of footwear. Concepts associated with the solestructure may be applied to a variety of athletic footwear types,including soccer shoes, running shoes, baseball shoes, basketball shoes,cross-training shoes, cycling shoes, football shoes, golf shoes, tennisshoes, walking shoes, and hiking shoes and boots, for example. Theconcepts may also be applied to footwear types that are generallyconsidered to be non-athletic, including dress shoes, loafers, sandals,and work boots. Accordingly, the concepts disclosed herein apply to awide variety of footwear types.

FIGS. 1 and 2 illustrate isometric views of an embodiment of solestructure 100. In particular, FIG. 1 illustrates an isometric view of abottom side of sole structure 100, while FIG. 2 illustrates an isometricview of a top side of sole structure 100. For purposes of illustration,sole structure 100 is shown in isolation in FIGS. 1 and 2. In someembodiments, sole structure 100 could be incorporated into the sole ofan article and/or associated with an upper. Sole structure 100 maygenerally comprise any portion of a sole for an article of footwear. Forexample, in some cases, sole structure 100 could comprise a portion ofan insole. In other cases, sole structure 100 could comprise a portionof a midsole. In one embodiment, sole structure 100 could comprise anoutsole for an article that is configured to come into contact with aground surface. In some embodiments, sole structure 100 may form theentire outsole of an article of footwear. In other embodiments, solestructure 100 may form only a portion of an outsole of an article offootwear. Moreover, in cases where sole structure 100 comprises anoutsole, sole structure 100 could be attached to any other component ofa sole structure (such as a midsole or insole). In other cases, solestructure 100 could be attached directly to an upper of an article offootwear. Additionally, in other embodiments, different configurationsof sole structure 100 may be included in an article of footwear.

For purposes of reference, components of sole structure 100 may bedivided into forefoot portion 10, midfoot portion 12 and heel portion14. Forefoot portion 10 may be generally associated with the toes andjoints connecting the metatarsals with the phalanges. Midfoot portion 12may be generally associated with the arch of a foot. Likewise, heelportion 14 may be generally associated with the heel of a foot,including the calcaneus bone. In addition, sole structure 100 mayinclude lateral side 16 and medial side 18. In particular, lateral side16 and medial side 18 may be opposing sides of sole structure 100.Furthermore, both lateral side 16 and medial side 18 may extend throughforefoot portion 10, midfoot portion 12 and heel portion 14.

It will be understood that forefoot portion 10, midfoot portion 12 andheel portion 14 are only intended for purposes of description and arenot intended to demarcate precise regions of sole structure 100.Likewise, lateral side 16 and medial side 18 are intended to representgenerally two sides of a sole structure, rather than preciselydemarcating sole structure 100 into two halves. In addition, forefootportion 10, midfoot portion 12 and heel portion 14, as well as lateralside 16 and medial side 18, can also be applied to individual componentsof a sole structure, such as a sockliner, insole or any other component.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal” as used throughout this detaileddescription and in the claims refers to a direction extending a lengthof a component. In some cases, the longitudinal direction may extendfrom a forefoot portion to a heel portion of the sole structure. Also,the term “lateral” as used throughout this detailed description and inthe claims refers to a direction extending a width of the solestructure. In other words, the lateral direction may extend between amedial side and a lateral side of the sole structure. Furthermore, theterm “vertical” as used throughout this detailed description and in theclaims refers to a direction generally perpendicular to a lateral andlongitudinal direction. For example, in cases where a sole structure isplanted flat on a ground surface, the vertical direction may extend fromthe ground surface upward. In addition, the term “proximal” refers to aportion of a footwear component that is closer to a portion of a footwhen an article of footwear is worn. Likewise, the term “distal” refersto a portion of a footwear component that is further from a portion of afoot when an article of footwear is worn. It will be understood thateach of these directional adjectives may be applied to individualcomponents of an article and/or a sole structure.

In some embodiments, sole structure 100 may comprise plate member 103.In some cases, plate member 103 can be a full length plate member,including a forefoot portion, a midfoot portion and a heel portion. Inother cases, however, plate member 103 may be a partial length platemember. For example, in some cases, plate member 103 may only extendthrough the forefoot of an article of footwear.

In some embodiments, sole structure 100 can include a plurality of cleatmembers 102 disposed on lower surface 104 of plate member 103.Generally, the term “cleat member” as used throughout this detailedspecification and throughout the claims includes any provision disposedon a sole structure for increasing traction through friction orpenetration of a ground surface. In the current embodiment, plurality ofcleat members 102 includes first cleat member 110, second cleat member120, third cleat member 130, fourth cleat member 140, fifth cleat member150, and sixth cleat member 160. Although the current embodimentincludes six cleat members, in other embodiments, cleat members 102could include less than six cleat members. In still other embodiments,cleat members 102 could include more than six cleat members.

Generally, cleat members 102 could be disposed in any arrangement onplate member 103. In some cases, some of cleat members 102 could bedisposed in forefoot portion 10. In other cases, some of cleat members102 could be disposed in midfoot portion 12. In some cases, some ofcleat members 102 could be disposed in heel portion 14. In oneembodiment, first cleat member 110 and second cleat member 120 aredisposed in forefoot portion 10. Also, in one embodiment, third cleatmember 130 and fourth cleat member 140 are disposed in midfoot portion12. Additionally, in one embodiment, fifth cleat member 150 and sixthcleat member 160 are disposed in heel portion 14. However, any otherarrangement of cleat members 102 are possible. For example, the currentembodiment includes cleat members that are disposed on a peripheralportion 106 of plate member 103. In other cases, however, some cleatmembers could be disposed more centrally on plate member 103.

It will be understood that the embodiments are not limited to cleatmembers having a particular shape and/or geometry. For example, someembodiments could incorporate cleat members having different geometriesand/or shapes, which may be selected according to various factorsincluding desired traction properties, weight properties, stabilityproperties as well as possible other factors. In some cases, forexample, the geometry and/or shape of one or more cleat members couldvary according to the intended sport for which sole structure 100 may beused. In particular, the geometry and/or shape of one or more cleatmembers could be selected according to whether sole structure 100 isintended for use in football, soccer, baseball, golf as well as possiblyother sports, as each sport may be associated with cleats havingparticular geometric characteristics.

Some embodiments may include provisions for reducing the overall weightof sole structure 100 while maintaining durability of cleat members 102.In some cases, for example, a portion of a cleat member could beintegrally formed with a plate member. In some cases, a portion of acleat member can comprise a protruding portion that is integral with aplate member.

In some embodiments, plate member 103 includes protruding portion 112(shown in an enlarged cross-section within FIG. 1) that is integrallyformed with plate member 103. Protruding portion 112 may include anouter portion 114 that extends out in a convex manner from lower surface104 of plate member 103. Protruding portion 112 may also include aninner portion 116 that is recessed in a concave manner with respect toupper surface 105 of plate member 103. With this configuration,protruding portion 112 provides an integrally formed first portion 118for first cleat member 110 that extends outwardly from lower surface 104of plate member 103.

In some embodiments, first cleat member 110 further includes secondportion 119. In some cases, second portion 119 comprises first pair ofcleat tip portions 170. First pair of cleat tip portions 170 includesfirst cleat tip portion 171 and second cleat tip portion 172 that arespaced apart by gap 173. In other embodiments, second portion 119 couldinclude a single cleat tip portion. In still other embodiments, secondportion 119 could include three or more distinct cleat tip portions.

In some embodiments, second portion 119 can also include connectingportion 174. In some cases, connecting portion 174 wraps aroundsidewalls 115 of protruding portion 112. Connecting portion 174 may beconfigured to connect first cleat tip portion 171 with second cleat tipportion 172. Moreover, in some cases, connecting portion 174 can providea connection between pair of cleat tip portions 170 and any otherportions of sole member 100.

A sole member can include provisions for increasing the strength of aprotruding portion. In some embodiments, a protruding portion can beconfigured with a supporting structure. A supporting structure can beany structure configured to reinforce or otherwise enhance support for aprotruding portion. In some cases, a supporting structure can also helpto anchor one or more cleat tip portions to a protruding portion.

In some embodiments, protruding portion 112 can be associated with firstsupporting structure 180. In some cases, first supporting structure 180may comprise a lattice like structure that is disposed within innerportion 116 of protruding portion 112. In some cases, first supportingstructure 180 comprises a plurality of intersecting ribs or walls thatare arranged approximately along the longitudinal and lateral directionsof protruding portion 112.

In different embodiments, the geometry of supporting structure 180 canvary. Any three-dimensional geometry and/or two-dimensional geometrycould be used for supporting structure 180. In some cases, supportingstructure 180 has a square or rectangular lattice-like cross-sectionalgeometry. In other cases, supporting structure 180 could have ahexagonal lattice-like, or honeycomb shaped, cross-sectional geometry.In still other cases, the cross-sectional geometry could be associatedwith any other shapes including triangles, rectangles, circles,ellipses, polygons, regular shapes as well as irregular shapes.Moreover, the pattern associated with supporting structure 180 could beconstant or could vary over different regions. It will be understoodthat the geometry of a supporting structure could be selected accordingto the desired strength characteristics for a protruding portion as wellas the geometry of the protruding portion.

In some embodiments, supporting structure 180 could extend throughoutthe substantial entirety of inner portion 116. In other cases,supporting structure 180 could extend through only a part of innerportion 116. In some cases, a supporting structure 180 could have avariable height that is contoured to fit the shape of inner portion 116.In some cases, surface 182 of supporting structure 180 could beapproximately flush with upper surface 105 of plate member 103.

In some embodiments, protruding portion 112 can include first hole 191and second hole 192. In some cases, supporting structure 180 and firstpair of cleat tip portions 170 can be connected through first hole 191and second hole 192. In some cases, first pair of cleat tip portions 170and supporting structure 180 comprise a substantially continuousmaterial portion that are joined through first hole 191 and second hole192. This arrangement helps to anchor pair of cleat tip portions 170 toprotruding portion 112.

In some embodiments, each of the remaining cleat members may beconfigured in a similar manner to first cleat member 110. For example,each of second cleat member 120, third cleat member 130, fourth cleatmember 140, fifth cleat member 150 and sixth cleat member 160 includecorresponding protruding portion 220, protruding portion 230, protrudingportion 240, protruding portion 250 and protruding portion 260,respectively, which may be collectively referred to along withprotruding portion 112 as protruding portions 280. Each protrudingportion includes a corresponding convex outer portion along lowersurface 104 and a corresponding concave inner portion along uppersurface 105. In some cases, protruding portion 240 and protrudingportion 260 could be continuous with one another, forming intermediateridge portion 210 on lower surface 104. Likewise, in some cases,protruding portion 230 and protruding portion 250 could be continuouswith one another, forming intermediate ridge portion 212 on lowersurface 104. In other cases, however, plate member 103 may not includeridge portion 210 and/or ridge portion 212.

In some embodiments, each of second cleat member 120, third cleat member130, fourth cleat member 140, fifth cleat member 150 and sixth cleatmember 160 may include corresponding pair of tip portions 226, pair oftip portions 236, pair of tip portions 246, pair of tip portions 256 andpair of tip portions 266, respectively, which may be collectivelyreferred to along with pair of tip portions 170 as plurality of cleattip portions 286. In other embodiments, some cleat members can includecleat tip portions, while others may not include cleat tip portions. Inother words, in some cases, cleat tip portions may be optional.

In some embodiments, each of second cleat member 120, third cleat member130, fourth cleat member 140, fifth cleat member 150 and sixth cleatmember 160 may include corresponding connecting portion 228, connectingportion 238, connecting portion 248, connecting portion 258 andconnecting portion 268, respectively, which may be collectively referredto along with connecting portion 174 as plurality of connecting portions290. In other embodiments, some cleat members can include connectingportions, while others may not include connecting portions. In otherwords, in some cases, connecting portions may be optional.

In some embodiments, each of cleat members 102 can also include acorresponding supporting structure. For example, in some cases, secondcleat member 120, third cleat member 130, fourth cleat member 140, fifthcleat member 150 and sixth cleat member 160 may include correspondingsupporting structure 225, supporting structure 235, supporting structure245, supporting structure 255 and supporting structure 265,respectively, which may be referred to collectively as plurality ofsupporting structures 296. In other embodiments, some cleat members caninclude supporting structures, while others may not include supportingstructures. In other words, in some cases, supporting structures may beoptional.

Using this arrangement, each cleat member can be configured in a similarmanner. In particular, each cleat member comprises a first portion thatis integrally formed with a plate member and provides a base likeprotruding portion for the cleat. Additionally, each cleat membercomprises a second portion that is attached to the first portion, wherethe second portion comprises cleat tip portions that further enhance thetraction provided by the cleat member. Moreover, to reduce weight andmaintain strength for each cleat member, each cleat member is formedwith a hollow inner portion that is filled with a supporting structure.For example, plurality of protruding portions 280 are filled withplurality of supporting structures 296. The supporting structures helpincrease the structural integrity of the cleat member and can provideanchoring for cleat tip portions 286.

In some embodiments, plurality of cleat tip portions 286 may beintegrally formed with plurality of connecting portions 290. Moreover,each of connecting portions 290 can be connected to peripheral layer 298that extends around peripheral portion 106 of plate 103 on lower surface104. In some cases, as discussed in further detail below, plurality ofcleat tip portions 286, plurality of connecting portions 290 andperipheral layer 298 may comprise a single molded layer that is disposedover lower surface 104 of plate member 103. In other cases, however,some of these various portions may not be connected to one another.

FIGS. 3 through 10 are intended to illustrate one embodiment of aprocess for making a sole structure including integrated cleat members.In some embodiments, some of the steps associated with the process couldbe accomplished by a proprietor, a manufacturer, a retailer or any otherentity. It will be understood that in some embodiments one or more ofthe steps associated with the process may be optional. In otherembodiments, some additional steps could be included that are notdiscussed below. Additionally, the order of the steps discussed belowcould be rearranged in any desired manner.

In different embodiments, plate member 103 can comprise differentmaterials with different characteristics. In some embodiments, platemember 103 can comprise a composite material. The term “compositematerial” as used throughout this detailed description and in theclaims, refers to any material made from two or more materials withdiffering material properties that retain some amount of separationwithin the composite material. In some cases, plate member 103 may bemade of a fiber-reinforced composite material including shortfiber-reinforced materials and continuous fiber-reinforced materials.Examples of fiber-reinforced materials include, but are not limited to:wood, carbon-fiber reinforced plastics and glass reinforced plastics. Inone embodiment, plate member 103 comprises a carbon fiber reinforcedcomposite. An exemplary composite structure is disclosed in Auger, U.S.Pat. No. 7,832,117, issued Nov. 16, 2010, the entirety of which ishereby incorporated by reference. In other cases, however, plate member103 could be made of any other materials, including materials withrelatively high rigidities or materials with relatively low rigidities.

In some cases, cleat tip portions 286, connecting portions 290 and/orsupporting structures 296 may comprise substantially similar materials.Examples of materials that could be used for these components include,but are not limited to: plastics, rubbers, metals as well as any othermaterials. In one embodiment, each of cleat tip portions 286, connectingportions 290 and supporting structures 296 may comprise a relativelysoft and/or flexible plastic material, such as thermoplasticpolyurethane (TPU). In other embodiments, these different portions couldcomprise different materials. For example, cleat tip portions 286 andsupporting structures 296 could be made of substantially differentplastic materials.

The arrangement described above provides an integrated cleat member witha strong base (a protruding portion) that is integrally formed withsubstantially rigid composite plate. This arrangement further provides acleat member with a more flexible cleat tip that provides foradaptability of the cleat tip on different kinds of surfaces andenhances penetration into a ground surface.

FIGS. 3 and 4 illustrate schematic views of an embodiment of a processfor forming a plurality of protruding portions on a plate member.Initially, as seen in FIG. 3, plate member 103 could be associated withshaping assembly 310. Initially, plate member 103 could be configuredwith any geometry. In some cases, plate member 103 may have anyapproximately two-dimensional geometry, such that the width and lengthare substantially greater than the depth of plate member 103. In othercases, the depth of plate member 103 could vary such that plate member103 is better described as three-dimensional. In some embodiments, platemember 103 could have a substantially flat geometry. For example, in oneembodiment, plate member 103 comprises a substantially flat layer. Inother embodiments, however, plate member 103 could have a curved orcontoured geometry. For example, in some cases, plate member 103 couldbe pre-shaped with the geometry of an outsole including a contouredperiphery that slopes upwardly towards a midsole component or upper ofan article of footwear.

As seen in FIG. 3, in an exemplary embodiment, plate member 103 may havea substantially flat geometry without any protrusions. In some cases,the geometry of plate member 103 could be slightly contoured.Additionally, in some cases, plate member 103 could be pre-shaped tohave an outer edge 302 that has the approximate shape of an outsole orother sole component.

It will be understood that in other embodiments, rather than startingwith a substantially flat plate member 103, other embodiments of themethod could start with a stock material that needs to be re-shaped andalso cut. For example, in some cases, a rectangular sheet of stockcomposite material may be shaped using shaping assembly 310 and then cutto the shape of an outsole or other sole component.

Shaping assembly 310 can be any machine or device known in the art forshaping or otherwise deforming various different kinds of materialsincluding rigid materials. In some cases, shaping assembly 310 comprisesa press that is configured to re-shape one or more portions of a rigidmaterial using pressure and/or heat. In particular, shaping assembly 310could include a top molding portion and a bottom molding portion thatare used to reshape a rigid material. In some embodiments, shapingassembly 310 may use pressure to reshape portions of plate member 103.In some cases, shaping assembly 310 may use heat to reshape portions ofplate member 103. In some cases, shaping assembly 310 may use heat andpressure to reshape portions of plate member 103. In one embodiment,shaping assembly 310 could be part of a device that uses an autoclavemolding technique to shape composite materials.

In one embodiment, shaping assembly 310 comprises top molding plate 312and bottom molding plate 314. In some cases, top molding plate 312 andbottom molding plate 314 provide molding surfaces that can be used toreshape on one or more portions of plate member 103. In some cases, topmolding plate 312 could be provided with protrusions 320. Additionally,bottom molding plate 314 could be provided with recesses 322 thatcorrespond with protrusions 320. As seen in FIGS. 3 and 4, to formprotrusions in plate member 103, protrusions 320 and recesses 322 of topmolding plate 312 and bottom molding plate 314 may be aligned onopposing sides of plate member 103. As top molding plate 312 and bottommolding plate 314 are pressed together, protruding portions 280 areformed. For example, in one embodiment, first portion 330 of platemember 103 is aligned with first protruding portion 331 of top moldingplate 312 and first recess 332 of bottom molding plate 314. As top mold312 and bottom bold 314 are pressed together, first portion 330 isreshaped to form first protruding portion 112, including concave innerportion 116 and convex outer portion 114.

Each of the remaining protruding portions discussed above, includingsecond protruding portion 220, third protruding portion 230, fourthprotruding portion 240, fifth protruding portion 250 and sixthprotruding portion 260 (see FIG. 1) can be formed in a similar mannerusing corresponding protrusions 320 and recesses 322 of shaping assembly310. Although the current embodiment illustrates a process for forming aplurality of protruding portions simultaneously, in other embodimentstwo or more different protrusions can be formed during different steps.For example, in some cases, protruding portions can be formed one at atime by applying a shaping assembly to a localized region of a platemember.

It will be understood that in still other embodiments, a plate member orsimilar sole component could be molded from a liquid and/or foam moldingmaterial. For example, in some other cases, a molding assembly can beused to form a sole component from a rubber and/or plastic material.

FIGS. 5 and 6 illustrate isometric views of upper surface 105 and lowersurface 104, respectively, of plate member 103 after being removed fromshaping assembly 310. As seen in FIGS. 5 and 6, plate member 103 hasbeen reshaped and includes protruding portions 280 that extend outwardlyfrom lower surface 104. At this stage in the process, plate member 103includes first protruding portion 112, second protruding portion 220,third protruding portion 230, fourth protruding portion 240, fifthprotruding portion 250 and sixth protruding portion 260. Each protrudingportion includes a corresponding inner concave portion and outer convexportion. For example, first protruding portion 112 includes innerportion 114 and outer portion 116.

FIG. 7 illustrates an embodiment of a possible step in the method whereholes are formed in one or more protruding portions. In one embodiment,two holes are formed in each protruding portion. For example, in thecurrent embodiment, first hole 191 and second hole 192 are formed infirst protruding portion 112. In some cases, first hole 191 and secondhole 192 may extend through the entire thickness of first protrudingportion 112. This allows fluid communication between outer portion 114and inner portion 116, as seen in FIG. 1. As seen in FIG. 7, holes mayalso be formed in each of second protruding portion 220, thirdprotruding portion 230, fourth protruding portion 240, fifth protrudingportion 250 and sixth protruding portion 260.

Although the current embodiment includes two holes for each protrudingportion, in other embodiments any other number of holes could be used.In some cases, each protruding portion could include a single hole. Instill other cases, each protruding portion could include more than twoholes. Moreover, in some cases, some protruding portions could includeholes, while other protruding portions may not include holes.

Generally, the shape and/or size of a hole can vary. In someembodiments, each hole may have an approximately circular shape. Inother cases, however, each hole could have any other shape including,but not limited to: triangular shapes, rectangular shapes, oval shapes,polygonal shapes, regular shapes and/or irregular shapes. In addition,the size of each hole could be varied in any manner.

Methods for forming holes in a plate member can vary. In one embodiment,each hole may be formed using water jet cutter 702 that uses highpressure and high velocity water to cut through rigid materials. Inother embodiments, however, holes could be formed using any othertechniques known in the art including, but not limited to laser cuttingtechniques, drilling and punching. In still other embodiments, holescould be formed simultaneously with a protruding portion. For example,in an embodiment where a portion of a plate member is reshaped to form aprotruding portion, a hole could be punched from the plate member as theprotruding portion is being formed using a molding plate.

FIGS. 8-10 illustrate embodiments of a method of forming cleat tipportions and support structures on a plate member. In particular, FIG. 8illustrates a schematic view of plate member 103 inserting into moldingassembly 800, while FIGS. 9 and 10 illustrate cross sectional views of aprotruding portion inside a portion of molding assembly 800.

Referring to FIG. 8, molding assembly 800 comprises top molding plate802 and bottom molding plate 804. For purposes of illustration, moldingassembly 800 is shown schematically in the current embodiment, howeverit will be understood that molding assembly 800 can be representative ofany type of molding device, machine or system known in the art.

In some embodiments, top molding plate 802 is configured with provisionsfor forming supporting structures. In one embodiment, top molding plate802 includes spacer portions 820. Spacer portions 820 compriseprojections that extend outwardly from top molding plate 802. In somecases, spacer portions 820 are integrally formed with top molding plate802. For example, in embodiments where top molding plate 802 comprises ametal material, spacer portions 820 may comprise a substantially similarmetal material. In other cases, however, spacer portions 820 may not beintegrally formed with top molding plate 802. In some other embodiments,for example, spacer portions 820 could be removable from top moldingplate 802.

In some embodiments, spacer portions 820 are arranged in sets thatcorrespond with each protruding portion of plate member 103. Forexample, first set of spacer portions 822 are configured to insert intoinner portion 116 of first protruding portion 112, as shown in FIG. 9.Likewise, second set of spacer portions 824, third set of spacerportions 826, fourth set of spacer portions 828, fifth set of spacerportions 830 and sixth set of spacer portions 832 are configured toinsert into second protruding portion 220, third protruding portion 230,fourth protruding portion 240, fifth protruding portion 250 and sixthprotruding portion 260, respectively.

Each set of spacer portions may be configured to create a correspondingsupporting structure during a molding process. For example, first set ofspacer portions 822 includes spacer portions approximately aligned intwo longitudinal rows and eight lateral rows. The spacer portions areseparated by gaps 831 where molding material may be filled in betweenthe spacer portions.

In some embodiments, the geometry of each spacer portion can be varied.In some embodiments, the shape of each spacer portion can be contouredso that each set of spacer portions has an overall shape correspondingto the approximate shape of an associated protruding portion. Forexample, in one embodiment, the spacer portions of first set of spacerportions 822 include contoured outer edges 840 that are contoured to theshape of outer edge 850 of first protruding portion 112. In some cases,the heights of one or more spacer portions could be constant. In othercases, the heights of one or more spacer portions could be varied toaccommodate the contours of first protruding portion 112. In the currentembodiment, the spacer portions of the majority of first set of spacerportions 822 have approximately constant heights. In this case, theoutermost spacer portions 839 have shorter heights to accommodate theslope of inner portion 116, as seen in FIG. 9.

In some embodiments, bottom molding plate 804 includes provisions forforming cleat tip portions on lower surface 104 of plate member 103. Inone embodiment, bottom molding plate 804 includes molding cavities 860.Molding cavities 860 comprise recesses that are sunken in from uppersurface 805 of bottom molding plate 804. Molding cavities 860 mayinclude first molding cavity 862, second molding cavity 864, thirdmolding cavity 866, fourth molding cavity 868, fifth molding cavity 870and sixth molding cavity 872, corresponding to first protruding portion112, second protruding portion 220, third protruding portion 230, fourthprotruding portion 240, fifth protruding portion 250 and sixthprotruding portion 260, respectively.

In some embodiments, each molding cavity may be shaped to formcorresponding cleat tip portions and connecting portions on a protrudingportion. For example, first molding cavity 862 can include recessedportion 880 that may receive sidewall portions 115 of first protrudingportion 112. In addition, first molding cavity 862 further includesfirst sub-recess 882 and second sub-recess 884, which are recessed withrespect to recessed portion 880. First sub-recess 882 and secondsub-recess 884 may be shaped to form first cleat tip portion 171 andsecond cleat tip portion 172 of first cleat member 110, as shown in FIG.1.

Each of the remaining molding cavities 860 can be configured in asubstantially similar manner to first molding cavity 862. In particular,each of second molding cavity 864, third molding cavity 866, fourthmolding cavity 868, fifth molding cavity 870 and sixth molding cavity872 can include similar recessed portions to form cleat tip portions andconnecting portions on second protruding portion 220, third protrudingportion 230, fourth protruding portion 240, fifth protruding portion 250and sixth protruding portion 260, respectively.

In some embodiments, bottom molding plate 804 can also includeperipheral cavity 890 that extends between molding cavities 860.Peripheral cavity 890 may be a relatively shallow cavity that is used toform peripheral layer 298 (see FIG. 1). In other embodiments, bottommolding plate 804 may not include peripheral cavity 890.

Referring to FIG. 9, with plate member 103 placed within moldingassembly 800, first set of spacer portions 822 of top molding plate 802are inserted into inner portion 116 of first protruding portion 112.Likewise, first protruding portion 112 is disposed within first moldingcavity 862 of bottom molding plate 804. At this point, injection nozzle900 may be aligned with an injecting port 902 of top molding plate 802.

For purposes of clarity, the current embodiment illustrates an injectionport 902 associated with top molding plate 802 in the region of firstset of spacer portions 822. However, in other embodiments, an injectionport could be associated with any other portion of molding assembly 800,including top molding plate 802 and/or bottom molding plate 804. Also,in some cases, multiple injection ports can be used at multiplelocations of molding assembly 800. For example, in one embodiment, eachset of spacer portions of top molding plate 802 could include a separateinjection port. In other cases, each molding cavity of bottom moldingplate 804 could include a separate injection port.

Next, as shown in FIG. 10, molding material 1000 injected through firstset of spacer portions 822. This allows the molding material to fillinto gaps 831 to form first supporting structure 180. Moreover, moldingmaterial 1000 may flow through first hole 191 and second hole 192 ofprotruding portion 112 into molding cavity 862. Thus, molding material1000 is able to cover sidewall portions 115 of first protruding portion112 to form first connecting portion 174. Also, molding material 1000may fill into first sub-recess 882 and second sub-recess 884 in order toform first cleat tip portion 171 and second cleat tip portion 172.

As previously discussed, molding material 1000 could comprise anymaterial. In some cases, molding material 1000 comprises a plasticmaterial, such as thermoplastic polyurethane (TPU). In other cases,however, molding material 1000 could be any other material. Moldingmaterial 1000 could be selected to achieve desired material propertiesfor cleat tip portions and connecting portions of a cleat member.

FIG. 11 illustrates an alternative embodiment of sole structure 100 inwhich the gaps of supporting structure 180 have been filled withmaterial 1102. In some cases, material 1102 can be inserted intosupporting structure 180 after support structure 180 has been formed. Inother cases, however, material 1102 could be formed substantiallysimultaneously with support structure 180, for example using amulti-shot molding process.

Generally, material 1102 could be any material. In some cases, material1102 could be a foam material. In other cases, material 1102 could be aplastic material. Material 1102 may be selected in order to achievedesired characteristics for cleat member 110. For example, to increasestrength and rigidity for cleat member 110, material 1102 could be arelatively rigid material. In other cases, to increase cushioning,material 1102 could be a foam or soft plastic material.

FIG. 12 illustrates a cross sectional view of an embodiment of anoptional step of a process for making a cleat member. Referring to FIG.12, in some embodiments, a protruding portion 1312 of a plate member1303 may be formed without any holes. In such cases, molding assembly800 can include a first injection nozzle 1302 and a second injectionnozzle 1304 associated with top molding plate 802 and bottom moldingplate 804. This allows a first material 1322 to be injected into innerportion 1316 of protruding portion 1312 and a second material 1324 to beinjected over outer portion 1314 of protruding portion 1312.

In some embodiments, first material 1322 and second material 1324 couldbe substantially different materials. In some cases, for example, firstmaterial 1322 could be substantially more rigid than second material1324. In other cases, second material 1324 could be substantially morerigid than first material 1322. In still other cases, first material1322 and second material 1324 could be substantially similar materials.For example, in one embodiment, first material 1322 and second material1324 could both be TPU.

Although the current embodiment illustrates a single layer of materialon outer portion 1314 of protruding portion 1312, other embodimentscould incorporate two or more layers. For example, another embodimentmay use two layers on outer portion 1314, where the outermost layercould be substantially more abrasion resistant than the layer directlyadjacent to outer portion 1314.

As seen in FIG. 13, the process shown in FIG. 12 provides a method ofmaking a sole structure 1400 with cleat member 1410. Cleat member 1410includes cleat tip portions 1470 and connecting portion 1474 on outerportion 1314 of protruding portion 1312 associated with outer surface1304 of plate member 1303. Moreover, supporting structure 1480 is formedon an inner portion 1316 of protruding portion 1312. Moreover, incontrast to the previous embodiments, cleat tip portions 1470 are notconnected to supporting structure 1480.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those in the art that many more embodiments and implementations arepossible that are within the scope of the current embodiments.Accordingly, the current embodiments are not to be restricted except inlight of the attached claims and their equivalents. Features describedin one embodiment may or may not be included in other embodimentsdescribed herein. Also, various modifications and changes may be madewithin the scope of the attached claims.

What is claimed is:
 1. A method of making a sole structure, comprising:reshaping a portion of a plate member to form a protruding portion for acleat member, the protruding portion having a convex outer portion and aconcave inner portion; forming a hole in the protruding portion, thehole providing fluid communication between the outer portion and theinner portion; molding a cleat tip portion onto the outer portion andmolding a supporting structure within the inner portion; and wherein thecleat tip portion is connected to the supporting structure through thehole.
 2. The method according to claim 1, wherein the plate membercomprises a composite material.
 3. The method according to claim 1,wherein the plate member is a carbon composite material.
 4. The methodaccording to claim 1, wherein the plate material comprises a firstmaterial and wherein the cleat tip portion comprises a second materialand wherein the first material is substantially more rigid than thesecond material.
 5. The method according to claim 1, wherein the cleattip portion is made of thermoplastic polyurethane.
 6. The methodaccording to claim 1, wherein the supporting structure comprises alattice-like structure.
 7. A method of making a sole structure,comprising: reshaping a portion of a plate member to form a protrudingportion for a cleat member, the protruding portion having a convex outerportion and a concave inner portion; filling the inner portion with amolding material to form a supporting structure; and wherein the platemember is substantially more rigid than the supporting structure.
 8. Themethod according to claim 7, wherein filling the inner portion with themolding material includes placing spacer portions into the inner portionand molding around the spacer portions to form a lattice-likeconfiguration.
 9. The method according to claim 7, wherein reshaping theportion of the plate member includes applying pressure to the platemember.
 10. The method according to claim 7, wherein the plate member isa composite material and wherein the supporting structure is made of aplastic material.
 11. The method according to claim 7, wherein themethod includes forming a cleat tip portion on the outer portion of theprotruding portion.
 12. The method according to claim 11, whereinforming the cleat tip portion includes molding the cleat tip portion onthe outer portion.
 13. The method according to claim 7, wherein themethod includes molding a peripheral layer onto a peripheral portion ofthe plate member.
 14. A sole structure, comprising: a plate membercomprising a first material, the plate member having a upper surface anda lower surface; a cleat member, the cleat member further comprising: afirst portion that is integrally formed with the plate member andincludes a concave inner portion on the upper surface of the platemember and a convex outer portion on the lower surface of the platemember; a second portion attached to the first portion, the secondportion comprising a second material; a support structure filling atleast a portion of the concave inner portion, the support structurebeing made of a third material; and wherein the first material issubstantially more rigid than the second material and wherein the firstmaterial is substantially more rigid than the third material.
 15. Thesole structure according to claim 14, wherein the second material andthe third material are substantially similar.
 16. The sole structureaccording to claim 14, wherein the second material and the thirdmaterial are substantially different.
 17. The sole structure accordingto claim 14, wherein the first material is a carbon fiber compositematerial.
 18. The sole structure according to claim 14, wherein thesecond material is thermoplastic polyurethane.
 19. The sole structureaccording to claim 14, wherein the third material is thermoplasticpolyurethane.
 20. The sole structure according to claim 14, wherein thefirst portion includes a hole providing fluid communication between theouter portion and the inner portion, and wherein the second portion isattached to the supporting structure through the hole.